U.S. patent application number 11/825041 was filed with the patent office on 2009-01-08 for glass laminates comprising acoustic interlayers and solar control films.
Invention is credited to Richard A. Hayes, Donald L. Rymer.
Application Number | 20090011230 11/825041 |
Document ID | / |
Family ID | 40221685 |
Filed Date | 2009-01-08 |
United States Patent
Application |
20090011230 |
Kind Code |
A1 |
Rymer; Donald L. ; et
al. |
January 8, 2009 |
Glass laminates comprising acoustic interlayers and solar control
films
Abstract
An acoustic solar control laminate comprising a multi-layer
interlayer formed of a solar control film bonded between two
polymeric sheets with at least one being an acoustic poly(vinyl
acetal) sheet is provided.
Inventors: |
Rymer; Donald L.; (Little
Hocking, OH) ; Hayes; Richard A.; (Beaumont,
TX) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY;LEGAL PATENT RECORDS CENTER
BARLEY MILL PLAZA 25/1122B, 4417 LANCASTER PIKE
WILMINGTON
DE
19805
US
|
Family ID: |
40221685 |
Appl. No.: |
11/825041 |
Filed: |
July 3, 2007 |
Current U.S.
Class: |
428/339 ;
428/428; 428/500 |
Current CPC
Class: |
B32B 17/10 20130101;
B32B 17/10761 20130101; Y10T 428/31649 20150401; Y10T 428/269
20150115; B32B 17/10174 20130101; Y10T 428/26 20150115; B32B
17/10036 20130101; Y10T 428/31855 20150401; Y10T 428/31645
20150401; Y10T 428/3163 20150401; Y10T 428/31627 20150401; B32B
17/10 20130101; B32B 2367/00 20130101; B32B 17/10005 20210101; B32B
2367/00 20130101 |
Class at
Publication: |
428/339 ;
428/500; 428/428 |
International
Class: |
B32B 9/00 20060101
B32B009/00; B32B 27/00 20060101 B32B027/00; B32B 17/10 20060101
B32B017/10 |
Claims
1. An acoustic solar control laminate comprising: (a) a first rigid
sheet; (b) a first polymeric sheet; (c) a polymeric film, which is
coated on at least one side with an infrared energy reflective
layer; (d) a second polymeric sheet; and (e) a second rigid sheet;
wherein the first rigid sheet is adhered to the first polymeric
sheet; the first polymeric sheet is adhered to the polymeric film;
the polymeric film is adhered to the second polymeric sheet; and
the second polymeric sheet is adhered to the second rigid sheet;
and further wherein the first polymeric sheet comprises an acoustic
poly(vinyl acetal) composition having a glass transition
temperature of 23.degree. C. or less; and wherein the first and the
second rigid sheets are each formed of a material having a modulus
of at least about 100,000 psi (690 MPa).
2. The acoustic solar control laminate of claim 1, wherein the
acoustic poly(vinyl acetal) composition comprises a poly(vinyl
acetal) produced by acetalizing a poly(vinyl alcohol) with one or
more aldehydes containing 6 to 10 carbon atoms.
3. The acoustic solar control laminate of claim 2, wherein the
poly(vinyl acetal) has an acetalization degree of at least about 50
mole %.
4. The acoustic solar control laminate of claim 2, wherein the
acoustic poly(vinyl acetal) composition further comprises a
plasticizer.
5. The acoustic solar control laminate of claim 1, wherein the
acoustic poly(vinyl acetal) composition comprises a poly(vinyl
acetal) having about 8 to about 30 mole % of acetoxy groups, based
on the total number of moles of vinyl groups in the poly(vinyl
acetal).
6. The acoustic solar control laminate of claim 5, wherein the
poly(vinyl acetal) is produced by acetalizing a poly(vinyl alcohol)
with an aldehyde containing 4 to 6 carbon atoms.
7. The acoustic solar control laminate of claim 6, wherein the
aldehyde is n-butyl aldehyde and the poly(vinyl acetal) is a
poly(vinyl butyral).
8. The acoustic solar control laminate of 5, wherein the acoustic
poly(vinyl acetal) composition further comprises a plasticizer.
9. The acoustic solar control laminate of claim 1, wherein the
acoustic poly(vinyl acetal) composition comprises a poly(vinyl
acetal) and about 40 to about 60 parts per hundred (pph) of a
plasticizer, based on 100 parts by weight of the poly(vinyl
acetal).
10. The acoustic solar control laminate of claim 9, wherein the
poly(vinyl acetal) is a poly(vinyl butyral).
11. The acoustic solar control laminate of claim 1, wherein the
acoustic poly(vinyl acetal) sheet has a thickness of at least about
0.25 mm.
12. The acoustic solar control laminate of claim 11, wherein the
acoustic poly(vinyl acetal) sheet has a thickness of about 0.38 to
about 1.74 mm.
13. The acoustic solar control laminate of claim 1, wherein the
second polymeric sheet comprises a second acoustic poly(vinyl
acetal) composition having a glass transition temperature of
23.degree. C. or less, and wherein the acoustic poly(vinyl acetal)
compositions in the first and second polymeric sheets may be the
same or different.
14. The acoustic solar control laminate of claim 1, wherein the
second polymeric sheet comprises a poly(ethylene-co-vinyl
acetate).
15. The acoustic solar control laminate of claim 1, wherein the
polymeric film comprises a polyester.
16. The acoustic solar control laminate of claim 15, wherein the
polymeric film comprises a poly(ethylene terephthalate).
17. The acoustic solar control laminate of claim 1, wherein the
infrared energy reflective layer comprises a metal layer or a
Fabry-Perot type interference filter layer.
18. The acoustic solar control laminate of claim 1, wherein each of
the first and second rigid sheets comprises a material selected
from glasses and polymers having a modulus of about 100,000 psi
(690 MPa) or greater, and wherein the materials of the first and
second rigid sheets may be the same or different.
19. The acoustic solar control laminate of claim 18, wherein the
first and second rigid sheets are glass sheets.
20. An acoustic solar control laminate consisting essentially of:
(a) a first glass sheet; (b) a first polymeric sheet comprising an
acoustic poly(vinyl acetal) composition having a glass transition
temperature of 23.degree. C. or less; (c) a polymeric film, which
is coated on at least one side with an infrared energy reflective
layer; (d) a second polymeric sheet; and (e) a second glass sheet;
wherein the first glass sheet is adhered to the first polymeric
sheet; the first polymeric sheet is adhered to the polymeric film;
the polymeric film is adhered to the second polymeric sheet; and
the second polymeric sheet is adhered to the second glass
sheet.
21. The acoustic solar control laminate of claim 20, wherein the
second polymeric sheet comprises a second acoustic poly(vinyl
acetal) composition having a glass transition temperature of
23.degree. C. or less; and wherein the first and second acoustic
poly(vinyl acetal) compositions may be the same or different.
22. The acoustic solar control laminate of claim 20, wherein the
second polymeric sheet comprises a poly(ethylene-co-vinyl acetate).
Description
FIELD OF THE INVENTION
[0001] The present invention relates to safety laminates with
improved sound damping and solar control properties.
BACKGROUND OF THE INVENTION
[0002] Glass laminated products have contributed to society for
almost a century. Beyond the well known, every day automotive
safety glass used in windshields, laminated glass is used in
windows for trains, airplanes, ships, and nearly every other mode
of transportation. Safety glass is characterized by high impact and
penetration resistance, and it does not scatter glass shards and
debris when shattered.
[0003] Safety glass typically consists of a sandwich of two glass
sheets or panels bonded together with an interlayer of a polymeric
film or sheet. One or both of the glass sheets may be replaced with
optically clear rigid polymeric sheets, such as sheets of
polycarbonate materials. Safety glass has further evolved to
include multiple layers of glass or rigid polymeric sheets bonded
together with interlayers that may include one or more polymeric
films or sheets.
[0004] The interlayer is typically made with a relatively thick
polymeric film or sheet, which exhibits toughness and bondability
to provide adhesion to the glass in the event of a crack or crash.
Over the years, a wide variety of polymeric interlayers have been
developed for use in safety glass. In general, these polymeric
interlayers must possess a combination of characteristics including
very high optical clarity, low haze, high impact resistance, high
penetration resistance, excellent ultraviolet light resistance,
good long term thermal stability, excellent adhesion to glass and
other rigid polymeric sheets, low moisture absorption, high
moisture resistance, and excellent long term weatherability. Widely
used interlayer materials include complex, multicomponent
compositions based on poly(vinyl butyral) (PVB), polyurethane (PU),
poly(vinyl chloride) (PVC), metallocene-catalyzed linear low
density polyethylenes (mPE or LLDPE), poly(ethylene-co-vinyl
acetate) (EVA), polymeric fatty acid polyamides, polyesters (e.g.,
poly(ethylene terephthalate) (PET)), silicone elastomers, epoxy
resins, elastomeric polycarbonates, and the like.
[0005] A more recent trend has been the use of glass laminated
products in the construction business for homes and office
structures. The use of architectural safety glass has expanded
rapidly over the years as designers have incorporated more glass
surfaces into buildings. In conjunction with this development,
threat resistance has become an ever increasing requirement for
architectural glass laminated products. Thus, newer safety glass
products are designed to resist both natural and man made
disasters. Examples of these needs include the recent developments
of hurricane resistant glass, now mandated in hurricane susceptible
areas, theft resistant glazings, and the more recent blast
resistant glass laminated products. These products have great
enough strength to resist intrusion even after the glass in the
laminate has been broken, for example, the interlayer maintains its
integrity against further insult when a glass laminate is subjected
to high force winds and impacts of flying debris as occur in a
hurricane or where there are repeated impacts on a window by a
criminal attempting to break into a vehicle or structure.
[0006] In addition, glass laminated products have now reached the
strength requirements for being incorporated as structural elements
within buildings. An example of this would be glass staircases now
being featured in many buildings.
[0007] Society continues to demand more functionality from
laminated glass products beyond the strength and safety
characteristics described above. One area of need is to reduce the
energy consumption within the structure, such as an automobile or
building, of which the laminated glass is a part. This need has
been met through the development of solar control laminated glass
structures. The solar energy strikes the earth over a wide spectral
range of from 350 nm to 2,100 nm, with the maximum intensity found
at 500 nm. The solar energy is divided into spectral regions, such
as the ultraviolet region of 449 nm or less, the visible region of
450 nm to 749 nm and the near infrared region of 750 nm to 2,100
nm. The solar energy intensity distribution across these spectral
regions is 4.44% for the ultraviolet region, 46.3% for the visible
region and 49.22% for the near infrared region. Removing the energy
from the visible region would sacrifice visual transparency through
windows and, therefore, detract from the purpose for having
windows. Since the near infrared region is not sensed by the human
eye, however, typical solar control glass laminates have attempted
to remove the energy from the near infrared region. For example,
the air conditioning load in the summer may be reduced in
buildings, automobiles and the like, which are equipped with solar
control windows that prevent the transmission of near infrared
radiation.
[0008] These solar control glass laminates may be obtained through
modification of the glass or of the polymeric interlayer, through
the addition of further solar control layers, or through
combinations of these techniques.
[0009] A recent trend has been the use of metal oxide
nanoparticles. These materials absorb the infrared light and
convert the energy to heat. To preserve the clarity and
transparency of the substrate, these materials need to have nominal
particle sizes below about 50 nanometers (nm).
[0010] Infrared-absorbing nanoparticles which have attained
commercial significance are antimony tin oxide (ATO) and indium tin
oxide (ITO). These nanoparticles are typically produced through
either a precipitation/calcination procedure or a flame pyrolysis
process. Antimony tin oxide particles and indium tin oxide
particles may be produced as disclosed within, e.g., U.S. Pat. No.
4,478,812; U.S. Pat. No. 4,937,148; U.S. Pat. No. 5,075,090; U.S.
Pat. No. 5,376,308; U.S. Pat. No. 5,772,924; U.S. Pat. No.
5,807,511; U.S. Pat. No. 5,518,810; U.S. Pat. No. 5,622,750; U.S.
Pat. No. 5,958,631; U.S. Pat. No. 6,051,166; and U.S. Pat. No.
6,533,966. These antimony tin oxide nanoparticles and indium tin
oxide nanoparticles have been incorporated into polymeric
interlayers of glass laminates or used to form solar control
coatings on film substrates.
[0011] A more recent trend has been the use of metal boride
nanoparticles, such as lanthanum hexaboride (LaB6). These materials
also absorb the infrared light and convert the energy to heat. To
preserve the clarity and transparency of the substrate, these
materials need to have nominal particle sizes below about 200
nanometers (nm).
[0012] A shortcoming of solar control laminates which incorporate
infrared absorptive materials is that a significant proportion of
the light absorbed serves to generate heat, some of which radiates
into the very structure that the solar control laminate was meant
to protect. This is especially true for stationary structures, such
as parked automobiles and buildings.
[0013] One development to produce solar control laminated glass is
the inclusion of metallized substrate films, such as polyester
films, which have metal layers, such as aluminum or silver metal,
applied thereon through a vacuum deposition or a sputtering
process. These supported metal stacks are disclosed in, e.g., U.S.
Pat. No. 3,718,535; U.S. Pat. No. 3,816,201; U.S. Pat. No.
3,962,488; U.S. Pat. No. 4,017,661; U.S. Pat. No. 4,166,876; U.S.
Pat. No. 4,226,910; U.S. Pat. No. 4,234,654; U.S. Pat. No.
4,368,945; U.S. Pat. No. 4,386,130; U.S. Pat. No. 4,450,201; U.S.
Pat. No. 4,465,736; U.S. Pat. No. 4,782,216; U.S. Pat. No.
4,786,783; U.S. Pat. No. 4,799,745; U.S. Pat. No. 4,973,511; U.S.
Pat. No. 4,976,503; U.S. Pat. No. 5,024,895; U.S. Pat. No.
5,069,734; U.S. Pat. No. 5,071,206; U.S. Pat. No. 5,073,450; U.S.
Pat. No. 5,091,258; U.S. Pat. No. 5,189,551; U.S. Pat. No.
5,264,286; U.S. Pat. No. 5,306,547; U.S. Pat. No. 5,932,329; U.S.
Pat. No. 6,391,400; and U.S. Pat. No. 6,455,141. The metallized
films are generally disclosed to reflect the appropriate light
wavelengths to provide the desired solar control properties. For
example, Fujimori, et. al., in U.S. Pat. No. 4,368,945, disclose an
infrared reflecting laminated glass for automobile consisting of an
infrared reflecting film with tungsten oxide layers between a
silver layer sandwiched between poly(vinyl butyral) layers which
incorporate ultraviolet absorbents. Brill, et. al., in U.S. Pat.
No. 4,450,201, disclose a multilayer heat barrier film. Nishihara,
et. al., in U.S. Pat. No. 4,465,736, disclose a laminate with a
selective light transmitting film. Woodard, in U.S. Pat. No.
4,782,216 and U.S. Pat. No. 4,786,783, discloses a transparent,
laminated window with near infrared rejection which included two
transparent conductive metal layers. Farmer, et. al., in U.S. Pat.
No. 4,973,511, disclose a laminated solar window construction which
includes a PET sheet with a multilayer solar coating. Woodard, in
U.S. Pat. No. 4,976,503, discloses an optical element for a motor
vehicle windshield which includes light-reflecting metal layers.
Hood, et. al., in U.S. Pat. No. 5,071,206, disclose reflecting
interference films. Moran, in U.S. Pat. No. 5,091,258, discloses a
laminate which incorporates an infra-red radiation reflecting
interlayer. Frost, et. al., in U.S. Pat. No. 5,932,329, disclose a
laminated glass pane comprising a transparent support film of a
tear-resistant polymer provided with an infrared-reflecting coating
and two adhesive layer. Woodard, et. al., in U.S. Pat. No.
6,204,480, disclose thin film conductive sheets for automobile
windows. Russell, et. al., in U.S. Pat. No. 6,391,400, disclose
dielectric layer interference effect thermal control glazings for
windows. Woodard, et. al., in U.S. Pat. No. 6,455,141, disclose a
laminated glass that incorporates an interlayer carrying an
energy-reflective coating. Kramling, et. al., in EP 0 418 123 B1,
disclose laminated glass with an interlayer comprising a copolymer
of vinyl chloride and glycidyl methacrylate with a plasticizer
content of 10 to 40 wt % or a thermoplastic polyurethane. The
interlayer may be coated with a reflecting film and the reflecting
film may have a surface resistivity of between 2 and 6 Ohms per
square. Longmeadow, in U.S. Pat. No. 7,157,133, discloses embossed
reflective laminates.
[0014] Laminated glass products are capable of providing even more
useful properties beyond the safety, display, and solar control
characteristics described above. One area of need is for the
automotive windshield to function as an acoustic barrier to reduce
the level of noise intrusion into the automobile. Acoustic
laminated glass is generally known within the art. For example,
Asahina, et. al., in U.S. Pat. No. 5,190,826, disclose a
sound-insulating interlayer for glass laminates, the interlayer in
the form of a laminated film comprising at least one resin film of
a poly(vinyl acetal) having a degree of acetalization of at least
50% prepared from an aldehyde having 6 to 10 carbon atoms and a
plasticizer and at least one resin film of a poly(vinyl acetal)
having a degree of acetalization of at least 50% prepared from an
aldehyde having 1 to 4 carbon atoms and a plasticizer or the
interlayer in the form of a laminated film comprising a mixture of
a poly(vinyl acetal) having a degree of acetalization of at least
50% prepared from an aldehyde having 6 to 10 carbon atoms, a
poly(vinyl acetal) having a degree of acetalization of at least 50%
prepared from an aldehyde having 1 to 4 carbon atoms and a
plasticizer. Ueda, et. al., in U.S. Pat. No. 5,340,654, disclose a
sound-insulating interlayer for glass laminates comprising
laminated layers of at least one layer which comprises a
plasticizer and a poly(vinyl acetal) resin which has 4 to 6 carbon
atoms in the acetal group and the average amount of ethylene groups
bonded to acetyl groups is 8 to 30 mole % and of at least one layer
which comprises a plasticizer and a poly(vinyl acetal) resin which
has 3 to 4 carbon atoms in the acetal group and the average amount
of ethylene groups bonded to acetyl groups is 4 mole % or less.
Rehfeld, et. al., in U.S. Pat. No. 5,368,917 and U.S. Pat. No.
5,478,615, disclose acoustic laminated glazings for vehicles
comprising conventional poly(vinyl butyral). The sound damping
properties of the poly(vinyl butyral) laminate described therein is
highly temperature dependent. Melancon, et. al., in U.S. Pat. No.
5,464,659, disclose radiation curable silicone/acrylate vibration
damping articles. Rehfeld, in U.S. Pat. No. 5,773,102, discloses
multilayer acoustic laminates comprising a non-acoustic layer and
an acoustic layer, wherein the acoustic layer may be composed of
certain plasticized terpoly(vinyl chloride-co-glycidyl
methacrylate-co-ethylene) materials. Hornsey, in U.S. Pat. No.
5,965,853, discloses a vibration dampening sound absorbing aircraft
transparency. Garnier, et. al., in U.S. Pat. No. 6,074,732,
disclose a soundproofing laminated window made of two glass sheets
with a PVB/PET/acrylate/PET/PVB interlayer. Benson, Jr., et. al.,
in U.S. Pat. No. 6,119,807, disclose sound dampening glazing which
includes a sheet of a sound dampening material. Landin, et. al., in
U.S. Pat. No. 6,132,882, disclose acoustic glass laminates which
incorporate certain acrylate acoustic layers. Friedman, et. al., in
U.S. Pat. No. 6,432,522, disclose an acoustical barrier glazing
which includes a multilayer interlayer. Yuan, et. al., in U.S. Pat.
No. 6,825,255, disclose certain plasticized poly(vinyl butyral)
sheets which include a fatty acid amide. Keller, et. al., in U.S.
Pat. No. 6,887,577, disclose acoustic glass laminates which
incorporate an acoustic layer of a plasticized poly(vinyl butyral)
which includes 50 to 80 wt % of a poly(vinyl butyral) and 20 to 50
wt % of a softener mixture. Bennison, et. al., in US 2006/0008648,
disclose a glass laminate interlayer having sound-damping
properties comprising a poly(vinyl butyral) resin having a hydroxyl
number in the range of from 17 to 23 and 40 to 50 parts per hundred
of a single plasticizer.
[0015] Accordingly, described herein are durable and safe glass
laminates with improved sound damping and solar control
properties.
SUMMARY OF THE INVENTION
[0016] Described herein is an acoustic solar control laminate
comprising: (a) a first rigid sheet; (b) a first polymeric sheet;
(c) a polymeric film, which is coated on at least one side with an
infrared energy reflective layer; (d) a second polymeric sheet; and
(e) a second rigid sheet, wherein the first rigid sheet is adhered
to the first polymeric sheet; the first polymeric sheet is adhered
to the polymeric film; the polymeric film is adhered to the second
polymeric sheet; and the second polymeric sheet is adhered to the
second rigid sheet, and further wherein the first polymeric sheet
comprises an acoustic poly(vinyl acetal) composition having a glass
transition temperature of 23.degree. C. or less; and wherein the
first and the second rigid sheets are each formed of a material
having a modulus of at least about 100,000 psi (690 MPa).
[0017] In one particular embodiment, the acoustic poly(vinyl
acetal) composition used here comprises a poly(vinyl acetal)
produced by acetalizing a poly(vinyl alcohol) with an aldehyde
containing 6 to 10 carbon atoms. Or preferably, the poly(vinyl
acetal) has an acetalization degree of at least about 50 mole
%.
[0018] In another embodiment, the acoustic poly(vinyl acetal)
composition used herein comprises a poly(vinyl acetal) having about
8 to about 30 mole % of acetoxy groups, based on the total number
of moles of vinyl groups in the poly(vinyl acetal). Preferably, the
poly(vinyl acetal) is produced by acetalizing a poly(vinyl alcohol)
with an aldehyde containing 4 to 6 carbon atoms. More preferably,
the aldehyde used herein is a n-butyl aldehyde and the poly(vinyl
acetal) is a poly(vinyl butyral).
[0019] In yet another embodiment, the acoustic poly(vinyl acetal)
composition used herein comprises a poly(vinyl acetal) and about 40
to about 60 parts per hundred (pph) of a plasticizer, based on 100
parts by weight of the poly(vinyl acetal). And preferably, the
poly(vinyl acetal) is a poly(vinyl butyral).
[0020] In yet another embodiment, the acoustic poly(vinyl acetal)
sheet used herein has a thickness of at least about 0.25 mm, or
about 0.38 to about 1.74 mm.
[0021] In yet another embodiment, the second polymeric sheet used
herein comprises a second acoustic poly(vinyl acetal) composition
having glass transition temperatures of 23.degree. C. or less, and
wherein the acoustic poly(vinyl acetal) compositions in the first
and second polymeric sheets may be the same or different.
[0022] In yet another embodiment, the second polymeric sheet
comprises a poly(ethylene-co-vinyl acetate).
[0023] In yet another embodiment, the polymeric film used herein
comprises a polyester, or a poly(ethylene terephthalate).
[0024] In yet another embodiment, the infrared energy reflective
layer applied on the polymeric film comprises a metal layer or a
Fabry-Perot type interference filter layer.
[0025] In yet another embodiment, each of the first and second
rigid sheets used herein comprises a material selected from glasses
and polymers.
[0026] The invention is further directed to an acoustic solar
control laminate consisting essentially of: (a) a first glass
sheet; (b) a first polymeric sheet comprising an acoustic
poly(vinyl acetal) composition having a glass transition
temperature of 23.degree. C. or less; (c) a polymeric film, which
is coated on one side with an infrared energy reflective layer; (d)
a second polymeric sheet; and (e) a second glass sheet, wherein the
first glass sheet is adhered to the first polymeric sheet; the
first polymeric sheet is adhered to the polymeric film; the
polymeric film is adhered to the second polymeric sheet; and the
second polymeric sheet is adhered to the second glass sheet.
[0027] The invention is yet further directed to an acoustic solar
control laminate consisting essentially of: (a) a first glass
sheet; (b) a first polymeric sheet comprising a first acoustic
poly(vinyl acetal) composition having a glass transition
temperature of 23.degree. C. or less; (c) a polymeric film, which
is coated on one side with an infrared energy reflective layer; (d)
a second polymeric sheet comprising a second acoustic poly(vinyl
acetal) composition having a glass transition temperature of
23.degree. C. or less; and (e) a second glass sheet, wherein the
first glass sheet is adhered to the first polymeric sheet; the
first polymeric sheet is adhered to the polymeric film; the
polymeric film is adhered to the second polymeric sheet; and the
second polymeric sheet is adhered to the second glass sheet.
[0028] The invention is yet further directed to an acoustic solar
control laminate consisting essentially of: (a) a first glass
sheet; (b) a first polymeric sheet comprising an acoustic
poly(vinyl acetal) composition having a glass transition
temperature of 23.degree. C. or less; (c) a polymeric film, which
is coated on one side with an infrared energy reflective layer; (d)
a second polymeric sheet comprising a poly(ethylene-co-vinyl
acetate); and (e) a second glass sheet, wherein the first glass
sheet is adhered to the first polymeric sheet; the first polymeric
sheet is adhered to the polymeric film; the polymeric film is
adhered to the second polymeric sheet; and the second polymeric
sheet is adhered to the second glass sheet.
DETAILED DESCRIPTION OF THE INVENTION
[0029] All publications, patent applications, patents, and other
references mentioned herein are incorporated by reference in their
entirety. Unless otherwise defined, all technical and scientific
terms used herein have the same meaning as commonly understood by
one of ordinary skill in the art to which this invention belongs.
In case of conflict, the present specification, including
definitions, will control.
[0030] Although methods and materials similar or equivalent to
those described herein can be used in the practice or testing of
the invention, suitable methods and materials are described
herein.
[0031] The following definitions apply to the terms as used
throughout this specification, unless otherwise limited in specific
instances.
[0032] As used herein, the term "acoustic" refers to certain
poly(vinyl acetal) compositions for convenience in describing the
invention, although the actual materials may be called by other
names in some instances, and any poly(vinyl acetal) composition
having the general characteristics described herein for acoustic
poly(vinyl acetal) compositions can be used in practicing the
invention.
[0033] Unless stated otherwise, all percentages, parts, ratios,
etc., are by weight.
[0034] When an amount, concentration, or other value or parameter
is given as either a range, preferred range or a list of upper
preferable values and lower preferable values, this is to be
understood as specifically disclosing all ranges formed from any
pair of any upper range limit or preferred value and any lower
range limit or preferred value, regardless of whether ranges are
separately disclosed. Where a range of numerical values is recited
herein, unless otherwise stated, the range is intended to include
the endpoints thereof, and all integers and fractions within the
range. It is not intended that the scope of the invention be
limited to the specific values recited when defining a range.
[0035] When the term "about" is used in describing a value or an
end-point of a range, the disclosure should be understood to
include the specific value or end-point referred to.
[0036] As used herein, the terms "comprises," "comprising,"
"includes," "including," "containing," "characterized by," "has,"
"having" or any other variation thereof, are intended to cover a
non-exclusive inclusion. For example, a process, method, article,
or apparatus that comprises a list of elements is not necessarily
limited to only those elements but may include other elements not
expressly listed or inherent to such process, method, article, or
apparatus.
[0037] Further, unless expressly stated to the contrary, "or"
refers to an inclusive or and not to an exclusive or. For example,
a condition A or B is satisfied by any one of the following: A is
true (or present) and B is false (or not present), A is false (or
not present) and B is true (or present), and both A and B are true
(or present).
[0038] The transitional phrase "consisting of" excludes any
element, step, or ingredient not specified in the claim, closing
the claim to the inclusion of materials other than those recited
except for impurities ordinarily associated therewith. When the
phrase "consists of" appears in a clause of the body of a claim,
rather than immediately following the preamble, it limits only the
element set forth in that clause; other elements are not excluded
from the claim as a whole.
[0039] The transitional phrase "consisting essentially of" limits
the scope of a claim to the specified materials or steps and those
that do not materially affect the basic and novel characteristic(s)
of the claimed invention. "A `consisting essentially of` claim
occupies a middle ground between closed claims that are written in
a `consisting of` format and fully open claims that are drafted in
a `comprising` format." Optional additives as defined herein, at
levels that are appropriate for such additives, and minor
impurities are not excluded from a composition by the term
"consisting essentially of", however.
[0040] Where applicants have defined an invention or a portion
thereof with an open-ended term such as "comprising," it should be
readily understood that (unless otherwise stated) the description
should be interpreted to also describe such an invention using the
terms "consisting essentially of" or "consisting of."
[0041] Use of "a" or "an" are employed to describe elements and
components of the invention. This is done merely for convenience
and to give a general sense of the invention. This description
should be read to include one or at least one and the singular also
includes the plural unless it is obvious that it is meant
otherwise.
[0042] Polymers are sometimes referred to herein by the monomers
used to make them or the amounts of the monomers used to make them.
Such a description may not include a formal nomenclature used to
describe the final polymer or may not contain product-by-process
terminology. Nevertheless, any such reference to monomers and
amounts means that the polymer is made from those monomers or that
amount of the monomers, and also refers to the corresponding
polymers and compositions thereof.
[0043] The materials, methods, and examples herein are illustrative
only and, except as specifically stated, are not intended to be
limiting.
[0044] Provided herein are safety laminates having improved sound
damping and solar control properties. Specifically, described
herein is a safety laminate comprising a first and a second outer
layers formed of rigid sheets and a multi-layer interlayer
comprising a first and a second polymeric sheets and a solar
control film, wherein (a) the solar control film is bonded or
adhered between the first and the second polymeric sheets; (b) the
first polymeric sheet is formed of an acoustic poly(vinyl acetal)
composition; and (c) the second polymeric sheet is formed of any
suitable polymeric material. Polymeric materials suitable in
forming the second polymeric sheet include, but are not limited to,
poly(vinyl acetal)s (including acoustic poly(vinyl acetal)s); acid
copolymers of alpha-olefins and alpha,beta-ethylenically
unsaturated carboxylic acids having 3 to 8 carbons; ionomers
derived from partially or fully neutralized acid copolymers of
alpha-olefins and alpha,beta-ethylenically unsaturated carboxylic
acids having 3 to 8 carbons; poly(ethylene-co-vinyl acetate)s
(EVA); ethyl acrylic acetates (EM); ethyl methacrylates (EMAC); and
metallocene-catalyzed polyethylenes. In one preferred embodiment,
the second polymeric sheet is also formed of an acoustic poly(vinyl
acetal) composition wherein the two acoustic poly(vinyl acetal)
compositions used to form the two polymeric sheets may be the same
or different. In another preferred embodiment, the second polymeric
sheet is formed of a composition comprising a
poly(ethylene-co-vinyl acetate). In yet another preferred
embodiment, the second polymeric sheet is formed of a composition
comprising an ionomer.
[0045] In each of the above embodiments, the bonded layers are
adjacent layers. Moreover, the "second" layer of any film or sheet
may be the same as or different from the first layer of that film
or sheet. Furthermore, in some preferred embodiments of the
invention, the adjacent layers are directly laminated or adhered to
each other so that they are adjoining or, more preferably,
contiguous.
[0046] Moreover, the acoustic solar control laminates described
herein may comprise adhesive layers to enhance adhesion between the
constituent layers. Conventional adhesives, such as silanes or
poly(alkyl amines) can be useful as optional components. When one
or more adhesive layer is present, they may be the same or
different. Typically, however, the interlayers described herein do
not require an adhesive to promote adhesion to glass.
Polymeric Compositions
[0047] I. Acoustic Poly(Vinyl Acetal) Compositions:
[0048] In the present invention, "acoustic poly(vinyl-acetal)
composition" is used to mean that the poly(vinyl acetal)
composition has a glass transition temperature (Tg) of 23.degree.
C. or less. Preferably the Tg is about 20.degree. C. to about
23.degree. C. As used herein, the Tg of the poly(vinyl acetal)
composition is determined as described in US 2006/0210776 by
rheometric dynamic shear mode analysis using the following
procedure. A polymer sheet of an acoustic poly(vinyl acetal)
composition is molded into a sample disc of 25 mm in diameter. The
polymeric sample sheet is placed between two 25 mm diameter
parallel plate test fixtures of a Rheometrics Dynamic Spectrometer
II (available from Rheometrics, Incorporated, Piscataway, N.J.).
The polymer sample sheet is tested in shear mode at an oscillation
frequency of 1 Hertz as the temperature of the sample is increased
from -20.degree. C. to 70.degree. C. at a rate of 2.degree.
C./minute. The position of the maximum value of tan delta (damping)
plotted as dependent on temperature is used to determine glass
transition temperature.
[0049] In one preferred embodiment, the acoustic poly(vinyl acetal)
composition comprises at least one poly(vinyl acetal) with acetal
groups derived from reacting poly(vinyl alcohol) with one or more
aldehydes containing 6 to 10 carbon atoms. Preferably, the
poly(vinyl acetal)s are produced by acetalizing poly(vinyl
alcohol)s with one or more aldehydes containing 6 to 10 carbon
atoms to a degree of acetalization of at least 50 mole %. Preferred
poly(vinyl alcohol)s are those having an average polymerization
degree of from about 1000 to about 3000 and are at least 95 mole %
in saponification degree. Preferably the poly(vinyl alcohol)
contains residual acetoxy groups in the range of from about 2 to
about 0.01 mole % of the total of the main chain vinyl groups. The
aldehydes having 6 to 10 carbon atoms may include aliphatic,
aromatic or alicyclic aldehydes. The aliphatic aldehydes may
include straight chain or branched alkyl groups. Specific examples
of aldehydes having 6 to 10 carbon atoms include n-hexylaldehyde,
2-ethylbutyraldehyde, n-heptylaldehyde, n-octylaldehyde,
n-nonylaldehyde, n-decylaldehyde, benzaldehyde, and cinnamaldehyde.
The aldehydes may be used alone or in combinations. Preferably, the
aldehydes have 6 to 8 carbon atoms.
[0050] The poly(vinyl acetal)s in this embodiment may be produced
through any known art method. For example, the poly(vinyl acetal)s
may be prepared by dissolving the poly(vinyl alcohol) in hot water
to obtain an aqueous solution, adding the desired aldehyde and
catalyst to the solution which is maintained at the required
temperature to cause the acetalization reaction to proceed. The as
obtained reaction mixture is then maintained at an elevated
temperature to complete the reaction, followed by neutralization,
washing with water and drying to obtain the desired product in the
form of a resin powder.
[0051] Suitable poly(vinyl acetal) compositions in this embodiment
preferably further include one or more plasticizers. The
plasticizer(s) to be admixed with the above produced poly(vinyl
acetal)s may be a monobasic acid ester, a polybasic acid ester or
like organic plasticizer, or an organic phosphate or organic
phosphite plasticizer. Preferable specific examples of the
monobasic esters include glycol esters prepared by the reaction of
triethylene glycol with butyric acid, isobutyric acid, caproic
acid, 2-ethylbutyric acid, heptanoic acid, n-octylic acid,
2-ethylhexylic acid, pelagonic acid (n-nonylic acid), decylic acid,
and the like and mixtures thereof. Additional useful monobasic acid
esters may be prepared from tetraethylene glycol or tripropylene
glycol with the above mentioned organic acids. Preferable examples
of the polybasic acid esters include those prepared from adipic
acid, sebacic acid, azelaic acid, and the like and mixtures
thereof, with a straight-chain or branched-chain alcohol having 4
to 8 carbon atoms. Preferable examples of the phosphate or
phosphite plasticizers include tributoxyethyl phosphate,
isodecylphenyl phosphate, triisopropyl phosphite and the like and
mixtures thereof. More preferable plasticizers include monobasic
esters such as triethylene glycol di-2-ethylbutyrate, triethylene
glycol di-2-ethylhexoate, triethylene glycol dicaproate and
triethylene glycol di-n-octoate, and dibasic acid esters such as
dibutyl sebacate, dioctyl azelate and dibutylcarbitol adipate.
[0052] Preferably the plasticizer is used in an amount of about 30
to about 60 parts by weight per 100 parts by weight of the
poly(vinyl acetal). More preferably the plasticizer is used in an
amount of about 30 to about 55 parts by weight per 100 parts by
weight of the poly(vinyl acetal).
[0053] Further additives may also be incorporated into the acoustic
poly(vinyl acetal) composition. For example, metal salts of
carboxylic acids, including potassium, sodium, or the like alkali
metal salts of octylic acid, hexylic acid, butyric acid, acetic
acid, formic acid and the like, calcium, magnesium or the like
alkaline earth metal salts of the above mentioned acids, zinc and
cobalt salts of the above mentioned acids, and stabilizers, such as
surfactants such as sodium laurylsulfate and alkylbenzenesulfonic
acids may be included. Such acoustic poly(vinyl acetal)
compositions are described within, for example, U.S. Pat. No.
5,190,826.
[0054] In another preferred embodiment, the acoustic poly(vinyl
acetal) composition comprises at least one poly(vinyl acetal) with
acetoxy groups in the range of about 8 to about 30 mole % of the
total of the main chain vinyl groups. Preferably the acoustic
poly(vinyl acetal)s contain acetal groups derived from reacting
poly(vinyl alcohol)s with one or more aldehydes containing 4 to 6
carbon atoms. The aldehydes are preferably aliphatic, and, when
aliphatic, may include straight chain or branched alkyl groups.
These acoustic poly(vinyl acetal)s may be prepared from poly(vinyl
alcohol)s having an average degree of polymerization of about 500
to about 3000. More preferably, these poly(vinyl acetal)s may be
prepared from poly(vinyl alcohol)s having an average degree of
polymerization of about 1000 to about 2500. Specific examples of
aldehydes which incorporate from 4 to 6 carbon atoms include,
n-butyl aldehyde, isobutyl aldehyde, valeraldehyde, n-hexyl
aldehyde and 2-ethylbutyl aldehyde and mixtures thereof. Preferable
aldehydes which incorporate from 4 to 6 carbon atoms include
n-butyl aldehyde, isobutyl aldehyde and n-hexyl aldehyde and
mixtures thereof. More preferably, the aldehyde which incorporates
from 4 to 6 carbon atoms is a n-butyl aldehyde and the poly(vinyl
acetal) is poly(vinyl butyral). Preferably, the degree of
acetalization for the resulting poly(vinyl acetal) is 40 mole % or
greater, more preferably, 50 mole % or greater. These poly(vinyl
acetal)s may be prepared as described above or below. Useful
plasticizers as described above or below may also be included in
these acoustic poly(vinyl acetal) compositions. Preferably the
plasticizer is used in an amount of from about 30 to about 70 parts
by weight per 100 parts by weight of the poly(vinyl acetal), more
preferably about 35 to about 65 parts by weight per 100 parts by
weight of the poly(vinyl acetal). Further additives may be
incorporated into the acoustic poly(vinyl acetal) composition as
described above or below. Such acoustic plasticized poly(vinyl
acetal) compositions are described within, for example, U.S. Pat.
No. 5,340,654 and EP 1 281 690.
[0055] In yet another preferred embodiment, the acoustic poly(vinyl
acetal) composition comprises at least one poly(vinyl acetal) and
plasticizer(s) in an amount of about 40 to about 60 parts per
hundred (pph) (preferably about 40 to about 50 pph) based on 100
parts by weight of the poly(vinyl acetal)s. Preferably the
poly(vinyl acetal) is produced by acetalizing a poly(vinyl alcohol)
with at least 95 mole % saponification degree. Preferably the
acoustic poly(vinyl acetal) composition contains plasticizer in an
amount of about 40 to about 60 parts per hundred (pph) based on 100
parts by weight of the poly(vinyl acetal). Preferably the
poly(vinyl acetal) is a poly(vinyl butyral). Such acoustic
poly(vinyl butyral) compositions are disclosed within US
2006/008648; US 2006/0210776 and US 2006/0210782.
[0056] The acoustic poly(vinyl butyral) disclosed in this
embodiment will typically have a weight average molecular weight
ranging from about 30,000 to about 600,000 Daltons (Da), or
preferably, from about 45,000 to about 300,000 Da, or more
preferably, from about 200,000 to about 300,000 Da, as measured by
size exclusion chromatography using low angle laser light
scattering. The preferable poly(vinyl butyral) material will
incorporate 0 to about 10%, or preferably, 0 to about 3%, of
residual ester groups, calculated as polyvinyl ester, typically
acetate groups, with the balance being butyraldehyde acetal. The
poly(vinyl butyral) may also incorporate a minor amount of acetal
groups other than butyral, for example, 2-ethyl hexanal, as
disclosed within U.S. Pat. No. 5,137,954.
[0057] Within this embodiment, usable plasticizers are those known
within the art, for example, as disclosed within U.S. Pat. No.
3,841,890, U.S. Pat. No. 4,144,217, U.S. Pat. No. 4,276,351, U.S.
Pat. No. 4,335,036, U.S. Pat. No. 4,902,464, U.S. Pat. No.
5,013,779, and WO 96/28504. Preferable plasticizers include
diesters of polyethylene glycol such as triethylene glycol
di(2-ethylhexanoate), tetraethylene glycol diheptanoate and
triethylene glycol di(2-ethylbutyrate) and dihexyl adipate.
Preferably, the plasticizer is one that is compatible (that is,
forms a single phase with the poly(vinyl butyral) resin) in the
amounts described hereinabove with a poly(vinyl butyral) having a
hydroxyl number (OH number) of about 12 to about 23.
[0058] In the above acoustic poly(vinyl acetal) compositions, an
adhesion control additive, for, e.g., controlling the adhesive bond
between the rigid sheet layers and the acoustic poly(vinyl acetal)
sheets, may also be included. These are generally alkali metal or
alkaline earth metal salts of organic and inorganic acids.
Preferably, they are alkali metal or alkaline earth metal salts of
organic carboxylic acids having from 2 to 16 carbon atoms. More
preferably, they are magnesium or potassium salts of organic
carboxylic acids having from 2 to 16 carbon atoms. The adhesion
control additive is typically used in the range of about 0.001 to
about 0.5 wt % based on the total weight of the polymeric sheet
composition. Other additives, such as antioxidants, ultraviolet
absorbers, ultraviolet stabilizers, thermal stabilizers, colorants
and the like, such as described above and within U.S. Pat. No.
5,190,826, may also be added to the acoustic poly(vinyl butyral)
composition.
[0059] II. Poly(ethylene-co-vinyl acetate) Compositions:
[0060] The poly(ethylene-co-vinyl acetate) composition used here
comprises at least one poly(ethylene-co-vinyl acetate) having a
level of copolymerized vinyl acetate comonomers of about 10 to
about 50 wt %, or preferably, about 20 to about 40 wt %, or more
preferably, about 25 to about 35 wt %, based on the total weight of
the composition. The poly(ethylene-co-vinyl acetate) used herein
may further contain copolymerized residues of other unsaturated
comonomers. Specific examples of other unsaturated comonomers
include, but are not limited to, methyl acrylate, methyl
methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate,
propyl methacrylate, isopropyl acrylate, isopropyl methacrylate,
butyl acrylate, butyl methacrylate, isobutyl acrylate, isobutyl
methacrylate, tert-butyl acrylate, tert-butyl methacrylate, octyl
acrylate, octyl methacrylate, undecyl acrylate, undecyl
methacrylate, octadecyl acrylate, octadecyl methacrylate, dodecyl
acrylate, dodecyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl
methacrylate, isobornyl acrylate, isobornyl methacrylate, lauryl
acrylate, lauryl methacrylate, 2-hydroxyethyl acrylate,
2-hydroxyethyl methacrylate, glycidyl acrylate, glycidyl
methacrylate, poly(ethylene glycol) acrylate, poly(ethylene glycol)
methacrylate, poly(ethylene glycol) methyl ether acrylate,
poly(ethylene glycol) methyl ether methacrylate, poly(ethylene
glycol) behenyl ether acrylate, poly(ethylene glycol) behenyl ether
methacrylate, poly(ethylene glycol) 4-nonylphenyl ether acrylate,
poly(ethylene glycol) 4-nonylphenyl ether methacrylate,
poly(ethylene glycol) phenyl ether acrylate, poly(ethylene glycol)
phenyl ether methacrylate, dimethyl maleate, diethyl maleate,
dibutyl maleate, dimethyl fumarate, diethyl fumarate, dibutyl
fumarate, dimenthyl fumarate, vinyl propionate, acrylic acid,
methacrylic acid, fumaric acid, maleic acid, maleic anhydride and
the like and mixtures thereof. Preferably, the other unsaturated
comonomers are selected from the group consisting of methyl
acrylate, methyl methacrylate, butyl acrylate, butyl methacrylate,
glycidyl methacrylate, acrylic acid, methacrylic acid and mixtures
thereof. The poly(ethylene-co-vinyl acetate) used herein may
contain up to about 50 wt %, or preferably, up to about 25 wt %, of
the copolymerized residues of the other unsaturated comonomer,
based on the total weight of the composition.
[0061] The poly(ethylene-co-vinyl acetate) compositions used herein
may further contain suitable plasticizers, such as polybasic acid
esters and polyhydric alcohol esters, or such as dioctyl phthalate,
dihexyladipate, triethylene glycol-di-2-ethylbutylate, butyl
sebacate, tetraethylene glycol heptanoate, triethylene glycol
dipelargonate and the like and mixtures thereof. In general, the
plasticizer level within the poly(ethylene-co-vinyl acetate)
composition does not exceed about 5 wt %, based on the total weight
of the composition.
[0062] The poly(ethylene-co-vinyl acetate) composition used herein
may further incorporate an organic peroxide. Preferably, the
organic peroxide has a thermal decomposition temperature of about
70.degree. C. or greater, or more preferably, about 100.degree. C.
or greater, in a half-life of 10 hours. The selection of the
appropriate organic peroxide may be chosen by one skilled in the
art with consideration of sheet-forming temperature, process for
preparing the composition, curing (bonding) temperature, heat
resistance of body to be bonded, storage stability, and the like.
Specific examples of the suitable organic peroxide include, but are
not limited to, 2,5-dimethylhexane-2,5-dihydroperoxide,
2,5-dimethyl-2,5-(t-butylperoxy)hexane-3-di-t-butylperoxide,
t-butylcumyl peroxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane,
dicumyl peroxide, alpha,alpha'-bis(t-butylperoxyisopropyl)benzene,
n-butyl-4,4-bis(t-butylperoxy)valerate,
2,2-bis(t-butylperoxy)butane, 1,1-bis(t-butylperoxy)cyclohexane,
1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane,
t-butylperoxybenzoate, benzoyl peroxide, t-butylperoxyacetate,
methyl ethyl ketone peroxide,
2,5-dimethyl-2,5-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane,
1-bis(t-butylperoxy)cyclohexane,
2,5-dimethylhexyl-2,5-bisperoxybenzoate, t-butyl hydroperoxide,
p-menthane hydroperoxide, p-chlorobenzoyl peroxide, hydroxyheptyl
peroxide, chlorohexanone peroxide, octanoyl peroxide, decanoyl
peroxide, lauroyl peroxide, cumyl peroxyoctoate, succinic acid
peroxide, acetyl peroxide, t-butylperoxy(2-ethylhexanoate),
m-toluoyl peroxide, t-butylperoxyisobutylate and
2,4-dichlorobenzoyl peroxide and the like and mixtures thereof. The
organic peroxide level may be within the range of about 0.1 to
about 5 wt %, based on the total weight of the composition.
[0063] Alternatively, the poly(ethylene-co-vinyl acetate) resin may
be cured by light. In this instance, the organic peroxide may be
replaced in whole or in part with a photoinitiator or
photosensitizer. Preferably, the level of the photoinitiator is
within the range of about 0.1 to about 5 wt %, based on the total
weight of the composition. Specific examples of the suitable
photoinitiators include, but are not limited to, benzoin,
benzophenone, benzoyl methyl ether, benzoin ethyl ether, benzoin
isopropyl ether, benzoin isobutyl ether, dibenzyl,
5-nitroacenaphtene, hexachlorocyclopentadiene, p-nitrodiphenyl,
p-nitroaniline, 2,4,6-trinitroaniline, 1,2-benzanthraquinone,
3-methyl-1,3-diaza-1,9-benzanthrone and the like and mixtures
thereof.
[0064] To further improve or adjust the various properties thereof,
such as, mechanical strength, adhesion properties, optical
characteristics such as transparency, heat resistance,
light-resistance, rate of crosslinking and the like, the
poly(ethylene-co-vinyl acetate) compositions used herein may
further include acryloyl(oxy) group containing compounds,
methacryloyl(oxy) group containing compounds and/or epoxy group
containing compounds. These materials are preferably included at a
level of up to about 50 wt %, or more preferably, up to about 10 wt
%, or yet more preferably, about 0.1 to about 2 wt %, based on the
total weight of composition. Examples of the acryloyl(oxy) and
methacryloyl(oxy) group containing compounds include derivatives of
acrylic acid or methacrylic acid, such as esters and amides of
acrylic acid or methacrylic acid. Examples of the ester residue
include linear alkyl groups (e.g., methyl, ethyl, dodecyl, stearyl
and lauryl), a cyclohexyl group, a tetrahydrofurfuryl group, an
aminoethyl group, a 2-hydroxyethyl group, a 3-hydroxypropyl group,
3-chloro-2-hydroxypropyl group. Further, the esters include esters
of acrylic acid or methacrylic acid with polyhydric alcohol such as
ethylene glycol, triethylene glycol, polypropylene glycol,
polyethylene glycol, trimethylol propane or pentaerythritol. One
example of the amide is diacetone acrylamide. Examples of
polyfunctional compounds include esters of plural acrylic acids or
methacrylic acids with polyhydric alcohol such as glycerol,
trimethylol propane or pentaerythritol. Examples of the epoxy group
containing compounds include triglycidyl
tris(2-hydroxyethyl)isocyanurate, neopentylglycol diglycidyl ether,
1,6-hexanediol diglycidyl ether, allyl glycidyl ether, 2-ethylhexyl
glycidyl ether, phenyl glycidyl ether, phenol(ethyleneoxy)sub-5
glycidyl ether, p-tert-butylphenyl glycidyl ether, diglycidyl
adipate, diglycidyl phthalate, glycidyl methacrylate and butyl
glycidyl ether, and the like and mixtures thereof.
[0065] The poly(ethylene-co-vinyl acetate) composition used herein
may also incorporate a silane coupling agent to enhance the
adhesive strengths. Specific examples of the preferable silane
coupling agent may include, for example,
gamma-chloropropylmethoxysilane, vinyltriethoxysilane,
vinyltris(beta-methoxyethoxy)silane,
gamma-methacryloxypropylmethoxysilane, vinyltriacetoxysilane,
gamma-glycidoxypropyltrimethoxysilane,
gamma-glycidoxypropyltriethoxysilane,
beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane,
vinyltrichlorosilane, gamma-mercaptopropylmethoxysilane,
gamma-aminopropyltriethoxysilane,
N-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane, and the like
and mixtures thereof. These silane coupling agent materials are
preferably used at a level of up to about 5 wt %, or more
preferably, about 0.001 to about 5 wt %, based on the total weight
of the composition.
[0066] Poly(ethylene-co-vinyl acetate) compositions suitable for
the present invention may be obtained from the Bridgestone
Corporation (Nashville, Tenn. ("Bridgestone")), the Exxon Mobil
Corporation (Houston, Tex.), Specialized Technologies Resources,
Inc. (Enfield, Conn.), and E. I. du Pont de Nemours and Company
(Wilmington, Del. ("DuPont")).
[0067] III. Additives:
[0068] It is understood that the polymeric compositions disclosed
above may further comprise one or more suitable additives. The
additives may include fillers, plasticizers, processing aides, flow
enhancing additives, lubricants, pigments, dyes, colorants, flame
retardants, impact modifiers, nucleating agents, lubricants,
antiblocking agents such as silica, slip agents, thermal
stabilizers, UV absorbers, UV stabilizers, hindered amine light
stablizers, dispersants, surfactants, chelating agents, coupling
agents, adhesives, primers and the like.
[0069] The polymeric compositions may contain an effective amount
of a thermal stabilizer. Thermal stabilizers are well disclosed
within the art. Any thermal stabilizer may find utility herein.
Preferable general classes of thermal stabilizers include phenolic
antioxidants, alkylated monophenols, alkylthiomethylphenols,
hydroquinones, alkylated hydroquinones, tocopherols, hydroxylated
thiodiphenyl ethers, alkylidenebisphenols, O-, N- and S-benzyl
compounds, hydroxybenzylated malonates, aromatic hydroxybenzyl
compounds, triazine compounds, aminic antioxidants, aryl amines,
diaryl amines, polyaryl amines, acylaminophenols, oxamides, metal
deactivators, phosphites, phosphonites, benzylphosphonates,
ascorbic acid (vitamin C), compounds which destroy peroxide,
hydroxylamines, nitrones, thiosynergists, benzofuranones,
indolinones, and the like and mixtures thereof. This should not be
considered limiting. Essentially any thermal stabilizer can be
used. The compositions preferably incorporate 0 to about 1.0 wt %
of thermal stabilizers, based on the total weight of the
composition.
[0070] The polymeric compositions may contain an effective amount
of UV absorber(s). UV absorbers are well disclosed within the art.
Preferable general classes of UV absorbers include benzotriazoles,
hydroxybenzophenones, hydroxyphenyl triazines, esters of
substituted and unsubstituted benzoic acids, and the like and
mixtures thereof. This should not be considered limiting.
Essentially any UV absorber may be used. The compositions
preferably contain 0 to about 1.0 wt % of UV absorbers, based on
the total weight of the composition.
[0071] The polymeric compositions may contain an effective amount
of hindered amine light stabilizers (HALS). Hindered amine light
stabilizers are generally well disclosed within the art. Generally,
hindered amine light stabilizers are disclosed to be secondary,
tertiary, acetylated, N-hydrocarbyloxy substituted, hydroxy
substituted N-hydrocarbyloxy substituted, or other substituted
cyclic amines which further contain steric hindrance, generally
derived from aliphatic substitution on the carbon atoms adjacent to
the amine function. This should not be considered limiting.
Essentially any hindered amine light stabilizer may be used. The
compositions preferably contain 0 to about 1.0 wt % of hindered
amine light stabilizers, based on the total weight of the
composition.
Polymeric Sheets
[0072] The polymeric sheets used to form the multi-layer interlayer
are formed of any of the above described polymeric compositions.
The polymeric sheets may be multilayer polymeric sheets or
monolayer polymeric sheets. In a preferred embodiment, the
polymeric sheets are monolayer polymeric sheets based on
manufacturing ease, such as the ability to recycle scrap sheet back
into the sheeting process. Typically, any of these polymeric sheets
has a thickness of about 10 mils (0.25 mm) or greater, or
preferably, about 15 mils (0.38 mm) or greater, or more preferably,
about 30 mils (0.75 mm) or greater. To provide the properties
required for the expected performance of conventional poly(vinyl
butyral) sheeting, the thickness of an acoustic poly(vinyl acetal)
sheet used herein should be in the range of from about 15 to about
70 mils (about 0.38-about 1.75 mm), or preferably, about 20 to
about 60 mils (about 0.5-about 1.5 mm), or more preferably, about
30 to about 45 mils (about 0.76 to about 1.13 mm), at the thickest
point. In a preferred embodiment, the sheet thickness is
homogeneous across the width of the acoustic poly(vinyl acetal)
sheet, e.g.; the thickness is the same at all edges of the sheet.
As for a poly(ethylene-co-vinyl) sheet, it is preferred that the
thickness ranges from about 10 to about 70 mils (about 0.25-about
1.75 mm), or more preferably, about 15 to about 60 mils (about
0.38-about 1.5 mm), or yet more preferably, about 30 to about 45
mils (about 0.76-about 1.13 mm). The desired thickness of the sheet
may represent the use of one single sheet or may represent multiple
sheets having individual thicknesses such that when they are
stacked together they provide the desired total thickness of the
interlayer. The polymeric sheets used herein may be of any width
and length.
[0073] The polymeric sheets used herein may be formed by any
suitable process, such as extrusion, calendering, solution casting
or injection molding. The parameters for each of these processes
can be easily determined by one of ordinary skill in the art
depending upon viscosity characteristics of the polymeric
composition used and the desired thickness of the sheet.
[0074] The polymeric sheets are preferably formed by extrusion.
[0075] The polymeric sheets may have a smooth surface. Preferably,
the polymeric sheets have a roughened surface to effectively allow
most of the air to be removed from between the surfaces of the
laminate during the lamination process. This can be accomplished,
for example, by mechanically embossing the sheets after extrusion
or by melt fracture during extrusion of the sheets and the
like.
[0076] The polymeric sheets may be further modified to provide
valuable attributes to the sheets and to the laminates produced
therefrom. For example, the sheets may be treated by radiation, for
example E-beam treatment of the sheets. E-beam treatment of the
acoustic poly(vinyl acetal) sheets with an intensity in the range
of about 2 to about 20 MRd will provide an increase of about
20.degree. C. to about 50.degree. C. in the softening point (i.e.,
Vicat Softening Point) of the sheets. Preferably, the radiation
intensity is from about 2.5 to about 15 MRd.
Solar Control Films
[0077] The solar control films used herein may be any polymeric
films with an infrared energy reflective layer. Such an infrared
energy reflective layer may be a simple semi-transparent metal
layer or a series of metal/dielectric layers.
[0078] The stacks of metal/dielectric layers are commonly referred
to as interference filters of the Fabry-Perot type. Each layer may
be on the order of an angstrom (.ANG.) thick or thicker. The
thickness of the various layers in the filter is controlled to
achieve an optimum balance between the desirable infrared
reflectance while maintaining the accepted visible light
transmittance. The metal layers are separated (i.e. vertically in
the thickness direction) from each other by one or more dielectric
layers so the reflection of visible light from the metal layers
interferes destructively and thereby enhances the visible light
transmission. Suitable metals for the metal layers include, e.g.,
silver, palladium, aluminum, chromium, nickel, copper, gold, zinc,
tin, brass, stainless steel, titanium nitride, and alloys or
claddings thereof. For optical purposes, silver and silver-gold
alloys are preferred. Metal layer thickness generally ranges from
about 60 to about 200 .ANG., or preferably, from about 80 to about
140 .ANG.. In general, the dielectric material should be chosen so
that its refractive index is greater than the material outside the
coating it abuts. It is desired that dielectric materials with a
relatively high refractive index be used here. Preferably, the
dielectric material may have a refractive index greater than about
1.8, or more preferably, greater than about 2.0. Additionally, the
dielectric material should be transparent over the visible range.
Suitable dielectric materials for the dielectric layers include,
but are not limited to, zirconium oxide, tantalum oxide, tungsten
oxide, indium oxide, tin oxide, indium tin oxide, aluminum oxide,
zinc sulfide, zinc oxide, magnesium fluoride, niobium oxide,
silicon nitride, and titanium oxide. Preferably the dielectric
materials are selected from tungsten oxides, indium oxides, tin
oxides, and indium tin oxides.
[0079] Generally, the metal/dielectric layers are applied onto the
polymeric films through vacuum deposition processes, such as vacuum
evaporation processes or sputtering deposition processes. Examples
of such processes include resistance heated, laser heated or
electron-beam vaporization evaporation processes and DC or RF
sputtering processes (diode and magnetron) under normal and
reactive conditions.
[0080] In one preferred embodiment, the solar control film is in
the form of an interference filter film, such as those disclosed in
U.S. Pat. No. 4,799,745 and U.S. Pat. No. 4,973,511. In particular,
U.S. Pat. No. 4,799,745 discloses a transparent, infrared
reflecting composite film including a transparent plastic film
layer (e.g., a poly(ethylene terephthalate) film) and adhered to
one side of the film layer a filter coating, which is formed of at
least two transparent metal layers separated from one another by a
dielectric layer; and U.S. Pat. No. 4,973,511 discloses a solar
control film comprising a transparent plastic film layer (e.g., a
poly(ethylene terephthalate) film) and coated to one side of the
film layer a filter coating, which is formed of (i) at least one
metal layer and at least one adjacent adherent dielectric layer or
(ii) at least one metal layer and bonded on each side thereof at
least two dielectric layers.
[0081] In such films, the coating layers may be further adjusted to
reflect particular wave lengths of energy, in particular, heat and
other infrared wavelengths. For example, as it is generally known
within the art, varying the thickness and composition of a
dielectric layer spaced between two reflecting metal layers will
vary the optical transmittance/reflection properties considerably.
More specifically, varying the thickness of the spacing between the
dielectric layers varies the wave length associated with the
reflection suppression (or transmission enhancement) band. In
addition to the choice of metal, thickness also determines its
reflectivity. Generally, the thinner the layer, the less its
reflectivity is. To obtain desirable optical properties, the
thickness of the spacing between the dielectric layer(s) is
preferably about 200 to about 1200 .ANG., or more preferably, about
450 to about 1000 .ANG..
[0082] For automotive end-uses, the metal/dielectric stacks
preferably contain at least two near infrared reflecting metal
layers which in operative position transmit at least 70% visible
light of normal incidence measured as specified in ANSI Z26.1. For
architectural applications, the metal/dielectric stacks may have
lower levels of visible light transmittance. Preferably, however,
the visible light reflectance from the surface of the
metal/dielectric stack should be less than about 8%. The inclusion
of exterior dielectric layers in contact with the metal layer
surfaces opposite to the metal surfaces contacting spacing
dielectric layer(s) may further enhance anti-reflection
performance. The thickness of such exterior or outside dielectric
layer(s) is generally about 20 to about 600 .ANG., or preferably,
about 50 to about 500 .ANG..
[0083] The above description should not be considered limiting.
Essentially any polymeric film with a coating of infrared
reflecting material may find utility in the acoustic solar control
laminates described herein.
[0084] Commercial examples of solar control films coated with
metal/dielectric stacks are available from Southwall Technologies,
Inc. (Palo Alto, Calif. ("Southwall")) under the trade names of
XIR.TM. 70 and XIR.TM. 75.
Rigid Sheets
[0085] The two outer layers of the acoustic solar control safety
laminates are formed of rigid sheets, which may be selected from
glass or rigid transparent plastic sheets (such as sheets of
polycarbonate, acrylics, polyacrylate, poly(methyl methacrylate),
cyclic polyolefins (e.g., ethylene norbornene polymers),
polystyrene (preferably metallocene-catalyzed) and the like and
combinations thereof). Preferably, the rigid sheet comprises a
material with a modulus of about 100,000 psi (690 MPa) or greater
(as measured by ASTM Method D-638). Preferably the rigid sheet is
formed of glass, polycarbonate, poly(methyl methacrylate), or
combinations thereof. More preferably, the rigid sheet is a glass
sheet.
[0086] The term "glass" is meant to include not only window glass,
plate glass, silicate glass, sheet glass, low iron glass, and float
glass, but also includes colored glass, specialty glass which
includes ingredients to control, for example, solar heating, coated
glass with, for example, sputtered metals, such as silver or indium
tin oxide, for solar control purposes, E-glass, Toroglass,
Solex.RTM. glass (PPG Industries, Pittsburgh, Pa.) and the like.
Such specialty glasses are disclosed in, e.g., U.S. Pat. No.
4,615,989; U.S. Pat. No. 5,173,212; U.S. Pat. No. 5,264,286; U.S.
Pat. No. 6,150,028; U.S. Pat. No. 6,340,646; U.S. Pat. No.
6,461,736; and U.S. Pat. No. 6,468,934. The glass may also include
frosted or etched glass sheet. Frosted and etched glass sheets are
articles of commerce and are well disclosed within the common art
and literature. The type of glass to be selected for a particular
laminate depends on the intended use.
[0087] Adhesives and primers may be used to enhance the bond
strength between the laminate layers, if desired.
Lamination Process
[0088] The safety glass laminates disclosed herein may be produced
through autoclave and non-autoclave processes, as described
below.
[0089] In a conventional autoclave process, the first rigid sheet,
the multi-layer interlayer, and the second rigid sheet are
laminated together under heat and pressure. An interlayer for an
acoustic solar control laminate may comprise a first polymeric
sheet, a solar control film, and a second polymeric sheet, wherein
at least one of the polymeric sheets comprises an acoustic
poly(vinyl acetal) composition. Preferably, the rigid sheets have
been washed and dried. A typical rigid sheet is a 90 mil thick
annealed flat glass.
[0090] Before lamination, the individual layers are stacked in the
desired order to form the pre-press assembly. The assembly is then
placed into a bag capable of sustaining a vacuum ("a vacuum bag"),
the air is drawn out of the bag by a vacuum line or other means,
the bag is sealed while the vacuum is maintained (for example, in
the range of about 27-28 inches Hg (689-711 mm Hg)), and the sealed
bag is placed in an autoclave at a temperature of about 130.degree.
C. to about 180.degree. C., at a pressure of about 150 to about 250
psi (about 11.3 to about 18.8 bar), for about 10 to about 50
minutes. Preferably the bag is autoclaved at a temperature of about
120.degree. C. to about 160.degree. C. for 20 to about 45 minutes.
More preferably the bag is autoclaved at a temperature of about
135.degree. C. to about 160.degree. C. for about 20 to about 40
minutes. Most preferably the bag is autoclaved at a temperature of
about 145.degree. C. to about 155.degree. C. for about 25 to about
35 minutes. A vacuum ring may be substituted for the vacuum bag.
One type of suitable vacuum bags is disclosed within U.S. Pat. No.
3,311,517.
[0091] Alternatively, other processes may be used to produce the
laminates. Any air trapped within the glass/multi-layer
interlayer/glass assembly may be removed through a nip roll
process. For example, the assembly may be heated in an oven at
about 80.degree. C. to about 120.degree. C., preferably about
90.degree. C. to about 100.degree. C., for about 20 to about 40
minutes. Thereafter, the heated assembly is passed through a set of
nip rolls so that the air in the void spaces between the glass and
the interlayer may be squeezed out, and the edge of the assembly
sealed. The assembly at this stage is referred to as a
pre-press.
[0092] The pre-press assembly may then be placed in an air
autoclave where the temperature is raised to about 120.degree. C.
to about 160.degree. C., preferably about 135.degree. C. to about
160.degree. C., at a pressure of about 100 to about 300 psi,
preferably about 200 psi (14.3 bar). These conditions are
maintained for about 15 minutes to about 1 hour, preferably about
20 to about 50 minutes, after which, the air is cooled while no
more air is added to the autoclave. After about 20 to about 40
minutes of cooling, the excess air pressure is vented and the
laminates are removed from the autoclave. This should not be
considered limiting. Essentially any lamination process may be
used.
[0093] The laminates can also be produced through non-autoclave
processes. Such non-autoclave processes are disclosed, for example,
within U.S. Pat. No. 3,234,062; U.S. Pat. No. 3,852,136; U.S. Pat.
No. 4,341,576; U.S. Pat. No. 4,385,951; U.S. Pat. No. 4,398,979;
U.S. Pat. No. 5,536,347; U.S. Pat. No. 5,853,516; U.S. Pat. No.
6,342,116; U.S. Pat. No. 5,415,909; US 2004/0182493; EP 1 235 683
B1; WO 91/01880; and WO 03/057478 A1. Generally, the non-autoclave
processes include heating the pre-press assembly and the
application of vacuum, pressure or both. For example, the pre-press
may be successively passed through heating ovens and nip rolls.
[0094] The following examples are provided to describe the
invention in further detail. These examples, which set forth a
preferred mode presently contemplated for carrying out the
invention, are intended to illustrate and not to limit the
invention.
EXAMPLES
Analytical Methods
[0095] I. Determination of Loss Factor (.eta.):
[0096] In the following examples, the loss factor (.eta.) (a
measure of sound insulating properties) was determined from the
measurement of the input impedence of a glass beam sample. A glass
laminate (approximately 25 mm by 300 mm) was placed at its center
onto an impact button (15 mm diameter), and affixed thereto with a
cyanoacrylic glue. The impact button was supported on an impedence
head, which was used to apply a measured force to the specimen via
the impact button. The measured force was a white noise force
oscillating at a frequency between 0 and 7000 Hz. The loss factor
(.eta.) was then calculated using the formula:
.eta.=.DELTA.f.sub.i/f.sub.resi
where .DELTA.f.sub.i was the frequency difference between the
frequencies on the resonance curve (f.sub.resi) having an impedence
of 3 dB less than the maximum impedence. The specimen was held in
an environmental chamber at the desired set temperature before and
during the time in which the measurement was conducted. The
impedence head was connected to a dash pot, which was connected to
a power amplifier, which was connected to a noise generator. The
impedence was measured by processing the raw noise data with a fast
Fourier transform (FFT) analyzer/computer set-up. Such methods are
summarized, for example, in the ISO 140 test protocol.
[0097] II. Determination of Solar Control Properties:
[0098] In the following examples, the solar control properties were
measured according to the procedures set forth in ASTM test method
E424, ASTM test method E308, and in the ISO9050:2003 and ISO 13837
test methods using a Perkin Elmer Lambda 19 spectrophotometer.
Example 1
[0099] Glass laminates composed of a first glass layer, a first
acoustic poly(vinyl butyral) sheet, an XIR.TM. 75 Blue film
(Southwall), a second acoustic poly(vinyl butyral) sheet and a
second glass layer, in which the acoustic poly(vinyl butyral)
sheets comprised 100 parts per hundred (pph) of poly(vinyl butyral)
with a hydroxyl number of 18.5 and 46.5 pph of the plasticizer
tetraethylene glycol diheptanoate, were produced in the following
manner. The acoustic poly(vinyl butyral) sheets (12 inches by 12
inches (305 mm by 305 mm) by 40 mils thick), and the XIR.TM. 75
Blue film (12 inches by 12 inches (305 mm by 305 mm)) are
conditioned at 23% relative humidity (RH) at a temperature of
72.degree. F. overnight. The laminate layers are laid up and the
assembly is placed into a vacuum bag and heated to 90-100.degree.
C. for 30 minutes to remove any air contained between the layers of
the assembly. The assembly is then subjected to autoclaving at
135.degree. C. for 30 minutes in an air autoclave at a pressure of
200 psig (14.3 bar), as described above. The air is then cooled
without adding any further air to the autoclave. After 20 minutes
of cooling, when the air temperature is less than about 50.degree.
C., the excess pressure is vented, and the final laminate is
removed from the autoclave.
[0100] As described above, 25 mm by 277 mm samples were cut out of
the laminate and tested for the loss factor at various temperatures
and frequencies. At 10.degree. C., the loss factor was 0.071 at a
frequency of 250 Hz, 0.1222 at a frequency of 1222 Hz, 0.1373 at a
frequency of 2844 Hz, 0.1422 at a frequency of 4712 Hz, and 0.1357
at a frequency of 6961.1 Hz. At 20.degree. C., the loss factor was
0.2292 at a frequency of 215 Hz, 0.2655 at a frequency of 965 Hz,
0.2672 at a frequency of 2252 Hz, 0.2454 at a frequency of 3848 Hz,
and 0.2079 at a frequency of 5817.1 Hz. At 30.degree. C., the loss
factor was 0.4865 at a frequency of 180 Hz, 0.3450 at a frequency
of 887, Hz 0.2775 at a frequency of 2200 Hz, 0.2026 at a frequency
of 4124 Hz, and 0.1792 at a frequency of 6644.3 Hz.
[0101] As described above, 25 mm by 257 mm samples were cut out of
the laminate and tested for the loss factor at various temperatures
and frequencies. At 10.degree. C., the loss factor was 0.0728 at a
frequency of 333 Hz, 0.1261 at a frequency of 1573 Hz, 0.1539 at a
frequency of 3608 Hz, and 0.1602 at a frequency of 5968 Hz. At
20.degree. C., the loss factor was 0.2223 at a frequency of 283 Hz,
0.2542 at a frequency of 1264 Hz, 0.2517 at a frequency of 2928 Hz,
and 0.1960 at a frequency of 5034.1 Hz. At 30.degree. C., the loss
factor was 0.4874 at a frequency of 143 Hz, 0.3631 at a frequency
of 675 Hz, 0.3049 at a frequency of 1668 Hz, 0.2272 at a frequency
of 3080 Hz, and 0.1790 at a frequency of 4982.7 Hz.
Example 2
[0102] By the same process as used in Example 1, glass laminates
composed of a first glass layer, a first acoustic poly(vinyl
butyral) sheet, an XIR.TM. 70 film (Southwall), a second acoustic
poly(vinyl butyral) sheet and a second glass layer in which the
acoustic poly(vinyl butyral) sheets comprised 100 pph of poly(vinyl
butyral) with a hydroxyl number of 18.5 and 48.5 pph of the
plasticizer tetraethylene glycol diheptanoate, are prepared.
Example 3
[0103] By the same process used in Example 1, glass laminates
composed of a first glass layer, a first acoustic poly(vinyl
butyral) sheet, an XIR.TM. 75 Blue film (Southwall), a second
acoustic polyvinyl butyral sheet and a second glass layer, in which
the acoustic poly(vinyl butyral) sheets comprised 100 pph of
poly(vinyl butyral) with a hydroxyl number of 18.5 and 48.5 pph of
the plasticizer tetraethylene glycol diheptanoate, are
prepared.
Example 4
[0104] By the same process used in Example 1, glass laminates
composed of a first glass layer, a first acoustic poly(vinyl
butyral) sheet, an XIR.TM. 75 Green film (Southwall), a second
acoustic poly(vinyl butyral) sheet, and a second glass layer, in
which the acoustic poly(vinyl butyral) sheets comprised 100 pph of
poly(vinyl butyral) with a hydroxyl number of 18.5 and 48.5 pph of
plasticizer tetraethylene glycol diheptanoate, are prepared.
Example 5
[0105] By the same process used in Example 1, glass laminates
composed of a first glass layer, a Butacite.RTM. poly(vinyl
butyral) sheet (DuPont), a XIR.TM. 70 HP Auto film (Southwall), an
acoustic poly(vinyl butyral) sheet and a second glass layer, in
which the acoustic poly(vinyl butyral) sheets comprised 100 parts
pph of poly(vinyl butyral) with a hydroxyl number of 18.5 and 48.5
pph of the plasticizer tetraethylene glycol diheptanoate, were
prepared.
[0106] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.354 and
a visible transmission of 0.719.
Example 6
[0107] By the same process used in Example 1, glass laminates
composed of a first glass layer, an Evasafe.TM.
poly(ethylene-co-vinyl acetate) sheet (Bridgestone), a XIR.TM. 70
HP Auto film (Southwall), an acoustic poly(vinyl butyral) sheet and
a second glass layer, in which the acoustic poly(vinyl butyral)
sheet comprised 100 parts pph of poly(vinyl butyral) with a
hydroxyl number of 18.5 and 48.5 pph of the plasticizer
tetraethylene glycol diheptanoate, were prepared.
[0108] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.340 and
a visible transmission of 0.675.
Example 7
[0109] By the same process used in Example 1, glass laminates
composed of a first glass layer, a SentryGlas.RTM. Plus sheet
(DuPont), a XIR.TM. 70 HP Auto film (Southwall), an acoustic
poly(vinyl butyral) sheet and a second glass layer, in which the
acoustic poly(vinyl butyral) sheet comprised 100 pph of poly(vinyl
butyral) with a hydroxyl number of 18.5 and 48.5 pph of the
plasticizer tetraethylene glycol diheptanoate, were prepared.
[0110] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.357 and
a visible transmission of 0.696.
Example 8
[0111] By the same process used in Example 1, glass laminates
composed of a first glass layer, a Butacite.RTM. poly(vinyl
butyral) sheet (DuPont), a XIR.TM. 70 Auto Blue V.1 film
(Southwall), an acoustic poly(vinyl butyral) sheet and a second
glass layer, in which the acoustic poly(vinyl butyral) sheet
comprised 100 pph of poly(vinyl butyral) with a hydroxyl number of
18.5 and 48.5 pph of the plasticizer tetraethylene glycol
diheptanoate, were prepared.
[0112] The laminate was tested for solar control properties as
described above and found to have a solar transmission of 0.478 and
a visible transmission of 0.752.
Example 9
[0113] By the same process used in Example 1, glass laminates
composed of a first glass layer, an Evasafe.TM.
poly(ethylene-co-vinyl acetate) sheet (Bridgestone), a XIR.TM. 70
Auto Blue V.1 film (Southwall), an acoustic poly(vinyl butyral)
sheet and a second glass layer, in which the acoustic poly(vinyl
butyral) sheet comprised 100 pph of poly(vinyl butyral) with a
hydroxyl number of 18.5 and 48.5 pph of the plasticizer
tetraethylene glycol diheptanoate, were prepared.
[0114] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.456 and
a visible transmission of 0.712.
Example 10
[0115] By the same process used in Example 1, glass laminates
composed of a first glass layer, a SentryGlas.RTM. Plus sheet
(DuPont), a XIR.TM. 70 Auto Blue V.1 film (Southwall), an acoustic
poly(vinyl butyral) sheet, and a second glass layer, in which the
acoustic poly(vinyl butyral) sheet comprised 100 pph of poly(vinyl
butyral) with a hydroxyl number of 18.5 and 48.5 pph of the
plasticizer tetraethylene glycol diheptanoate, were prepared.
[0116] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.461 and
a visible transmission of 0.716.
Example 11
[0117] Glass laminates composed of a first glass layer, a
Butacite.RTM. poly(vinyl butyral) sheet (DuPont), a XIR.TM. 75
Green film (Southwall), an acoustic poly(vinyl butyral) sheet and a
second glass layer, in which the acoustic poly(vinyl butyral) sheet
comprised 100 pph of poly(vinyl butyral) with a hydroxyl number of
18.5 and 48.5 pph of the plasticizer tetraethylene glycol
diheptanoate, were prepared.
[0118] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.465 and
a visible transmission of 0.730.
Example 12
[0119] By the same process used in Example 1, glass laminates
composed of a first glass layer, an Evasafe.TM.
poly(ethylene-co-vinyl acetate) sheet (Bridgestone), a XIR.TM. 75
Green film (Southwall), an acoustic poly(vinyl butyral) sheet and a
second glass layer, in which the acoustic poly(vinyl butyral) sheet
comprised 100 pph of poly(vinyl butyral) with a hydroxyl number of
18.5 and 48.5 pph of the plasticizer tetraethylene glycol
diheptanoate, were prepared.
[0120] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.448 and
a visible transmission of 0.694.
Example 13
[0121] By the same process used in Example 1, glass laminates
composed of a first glass layer, a SentryGlas.RTM. Plus sheet
(DuPont), a XIR.TM. 75 Green film, (Southwall), an acoustic
poly(vinyl butyral) sheet and a second glass layer, in which the
acoustic poly(vinyl butyral) sheet comprised 100 pph of poly(vinyl
butyral) with a hydroxyl number of 18.5 and 48.5 pph of the
plasticizer tetraethylene glycol diheptanoate, were prepared.
[0122] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.435 and
a visible transmission of 0.688.
Example 14
[0123] By the same process used in Example 1, glass laminates
composed of a first glass layer, a Butacite.RTM. poly(vinyl
butyral) sheet (DuPont), a XIR.TM. Laminated 72-47 film
(Southwall), an acoustic poly(vinyl butyral) sheet and a second
glass layer, in which the acoustic poly(vinyl butyral) sheet
comprised 100 pph of poly(vinyl butyral) with a hydroxyl number of
18.5 and 48.5 pph of the plasticizer tetraethylene glycol
diheptanoate, were prepared.
[0124] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.419 and
a visible transmission of 0.710.
Example 15
[0125] By the same process used in Example 1, glass laminates
composed of a first glass layer, an Evasafe.TM.
poly(ethylene-co-vinyl acetate) sheet (Bridgestone), a XIR.TM.
Laminated 72-47 film (Southwall), an acoustic poly(vinyl butyral)
sheet and a second glass layer, in which the acoustic poly(vinyl
butyral) sheets comprised 100 pph of poly(vinyl butyral) with a
hydroxyl number of 18.5 and 48.5 pph of the plasticizer
tetraethylene glycol diheptanoate, were prepared.
[0126] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.400 and
a visible transmission of 0.674.
Example 16
[0127] By the same process used in Example 1, glass laminates
composed of a first glass layer, a SentryGlas.RTM. Plus sheet
(DuPont), a XIR.TM. Laminated 72-47 film (Southwall), an acoustic
poly(vinyl butyral) layer and a second glass layer, in which the
acoustic poly(vinyl butyral) sheet comprised 100 pph of poly(vinyl
butyral) with a hydroxyl number of 18.5 and 48.5 pph of the
plasticizer tetraethylene glycol diheptanoate, were prepared.
[0128] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.420 and
a visible transmission of 0.709.
Example 17
[0129] By the same process used in Example 1, glass laminates
composed of a first glass layer, a Butacite.RTM. poly(vinyl
butyral) sheet (DuPont), a XIR.TM. 70 HP film (Southwall), an
acoustic poly(vinyl butyral) sheet and a second glass layer, in
which the acoustic poly(vinyl butyral) sheet comprised 100 pph of
poly(vinyl butyral) with a hydroxyl number of 18.5 and 48.5 pph of
the plasticizer tetraethylene glycol diheptanoate, were
prepared.
[0130] The laminate was tested for solar control properties as
described above and found to have a solar transmission of 0.359 and
a visible transmission of 0.719.
Example 18
[0131] By the same process used in Example 1, glass laminates
composed of a first glass layer, an Evasafe.TM.
poly(ethylene-co-vinyl acetate) sheet (Bridgestone), a XIR.TM. 70
HP film (Southwall), an acoustic poly(vinyl butyral) sheet and a
second glass layer, in which the acoustic poly(vinyl butyral) sheet
comprised 100 pph of poly(vinyl butyral) with a hydroxyl number of
18.5 and 48.5 pph of the plasticizer tetraethylene glycol
diheptanoate, were prepared.
[0132] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.334 and
a visible transmission of 0.672.
Example 19
[0133] By the same process used in Example 1, glass laminates
composed of a first glass layer, a SentryGlas.RTM. Plus sheet
(DuPont), a XIR.TM. 70 HP film (Southwall), an acoustic poly(vinyl
butyral) sheet and a second glass layer, in which the acoustic
poly(vinyl butyral) sheet comprised 100 pph of poly(vinyl butyral)
with a hydroxyl number of 18.5 and 48.5 pph of the plasticizer
tetraethylene glycol diheptanoate, were prepared.
[0134] The laminates were tested for solar control properties as
described above and found to have a solar transmission of 0.355 and
a visible transmission of 0.708.
[0135] While certain of the preferred embodiments of the present
invention have been described and specifically exemplified above,
it is not intended that the invention be limited to such
embodiments. Various modifications may be made without departing
from the scope and spirit of the present invention, as set forth in
the following claims.
* * * * *